Composite seat cushion and method of making same

ABSTRACT

A cushion for a school bus seat can include a single piece of skinned foam including foam and a skin integrally bonded to the foam. The single piece of skinned form can include a cavity. The single piece of skinned foam can be configured to receive at least one of a substantially upright back portion of a school bus seat frame and a substantially horizontal seat portion of the school bus seat frame. The single piece of skinned foam can be configured to be disposed over and to cover at least one of the substantially upright back portion and the substantially horizontal seat portion.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority of U.S. Provisional ApplicationNo. 60/935,785, filed Aug. 30, 2007, and U.S. Provisional ApplicationNo. 60/996,067, filed Oct. 26, 2007, the contents of each of which ishereby incorporated by reference in its entirety.

BACKGROUND

The present invention relates generally to seat cushions and, morespecifically, to seat cushions used in buses or other large passengervehicles.

At present, seats for vehicles can be manufactured by assembling acushioned cover on a seat frame, such as the frame of a school bus seat.The cushioned cover is often formed by creating a foam envelope, Thefoam envelope can be created by first cutting or slicing foam into apredetermined thickness and into a front piece, back piece, and outerstrip. The strip is located between the front and back pieces andlaminated with an adhesive to create the foam envelope having a cavityor envelope shape, which is configured to cover the seat frame wheninstalled.

Additional materials may be added to the foam envelope. For example,Styrofoam kneepads can be added to enhance critical impact areas, e.g.,where a passenger's knee may come into contact with the cushioned cover.Additionally, fabric can be added to critical seams to add to qualityand longevity of the foam envelope.

After the foam envelope has been formed, it is fitted over the seatframe. A vinyl seat cover is then be placed over the foam envelope toassist in compartmentalization and to create a flame retardant barrier.The addition of the seat cover is typically required to meetregulations, such as FMVSS 222 and FMVSS 302 for school buses.

The seat can provide a higher level of safety by creatingcompartmentalization. More specifically, the seat is configured tomaintain the occupant within a particular space or compartment. Thecompartmentalization can be enhanced by using a high-back, well-paddedseat designed for specific crash standards.

The seat also should meet specific flammability standards. However, ifthe outer vinyl cover becomes damaged (e.g., due to vandalism),additional oxygen flow is permitted within the seat. In the event offire, the additional oxygen flow can increase the heat beyond the flashpoint of the foam and cause the seat to burn, thereby increasing thepotential for fires to spread within the bus.

In the conventional design, the foam envelope may break down within thevinyl cover and the seat frame can become exposed. This can compromisethe protection level provided by the foam. Additionally, the intendedcompartmentalization may become compromised.

SUMMARY

According to an exemplary embodiment, a cushion for a school bus seatcomprises a single piece of skinned foam including foam and a skinintegrally bonded to the foam. The single piece of skinned foam caninclude a cavity. The single piece of skinned foam can be configured toreceive at least one of a substantially upright back portion of a schoolbus seat frame and a substantially horizontal seat portion of the schoolbus seat frame. The single piece of skinned foam can be configured to bedisposed over and to cover at least one of the substantially uprightback portion and the substantially horizontal seat portion.

According to an exemplary embodiment, a method of making at least aportion of a school bus seat can include the steps of disposing within amold a material for forming a skin of the school bus seat and disposingon the material a foam material to form a single piece of skinned foam.The single piece of skinned foam can be configured to be disposed overand to cover at least one of a substantially upright back portion of aframe of a school bus seat and a substantially horizontal seat portionof a frame of a school bus seat.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a mold that is used to create a compositeseat cushion, according to an exemplary embodiment;

FIG. 2 is an isometric view of the mold of FIG. 1 with knee pad insertsin place and a material being introduced into the mold.

FIG. 3 is an isometric view of the mold of FIG. 1 in a closed position.

FIG. 4 is an isometric view of the composite seat cushion being removedfrom the mold, according to an exemplary embodiment;

FIG. 5 is a perspective view of the composite seat cushion, according toan exemplary embodiment;

FIG. 6 is an isometric view of the composite seat cushion of FIG. 4 froma rear view and showing the different thicknesses in specified areas,according to an exemplary embodiment;

FIG. 7 includes cross sectional drawings of the composite seat cushion,according to an exemplary embodiment;

FIG. 8 is a rear view of a seat back frame of a bus seat, according toan exemplary embodiment;

FIG. 9 is a rear view of the composite seat cushion being placed overthe seat back frame of FIG. 8, according to an exemplary embodiment;

FIG. 10 is a rear view of the composite seat cushion in place over theseat back frame of FIG. 8, according to an exemplary embodiment;

FIG. 11 is a front view of the composite seat cushion in place over theseat back frame of FIG. 8, according to an exemplary embodiment;

FIG. 12 is an isometric view of a composite seat cushion with anadditional aisle side barrier, according to an exemplary embodiment;

FIG. 13 is an isometric view of a composite seat cushion with anadditional rearward extending curvature, according to an exemplaryembodiment;

FIG. 14 is an isometric view of multiple seats with the composite seatcushion and the safety features illustrated in FIGS. 12 and 13,according to an exemplary embodiment;

FIG. 15 is an opposite side view of FIG. 14, according to an exemplaryembodiment;

FIG. 16 is a side view of the composite seat cushion of FIGS. 12 and 13with more pronounced safety features, according to an exemplaryembodiment; and

FIG. 17 is an isometric view of a completed assembly of a composite seatcushion and seat back frame incorporated with seat belts, according toan exemplary embodiment.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

According to various exemplary embodiments, the invention disclosedherein may be applied to various seats. The present disclosure uses aschool bus seat as an example of a seat where a composite seat cushionmay be used.

In general, a composite seat cushion according to the present inventioncan include a composite foam envelope configured to fit over a bus seatframe. FIG. 7 shows cross-sectional views of an embodiment of such acomposite seat cushion, wherein an envelope structure is provided bycreating a cavity in the mid-region of the composite seat cushion. Thecomposite seat cushion can include an outer “skin-like” surface and aninner “foam” or “foam-like” substance. The envelope is preferablydesigned to meet or exceed federally mandated specifications for such aproduct, providing safety in various conditions such as a fire or acollision event. Though shown as having a cavity, the composite seatcushion could be solid, if necessary.

FIGS. 1 through 6 illustrate an embodiment of a method of forming acomposite seat cushion according to the present invention.

FIG. 1 is a view of a mold 10 used to create a composite seat cushion,according to an exemplary embodiment. The mold 10 may be made of, forexample, aluminum. The mold 10 can include an inner core 1A that may beused to form a cavity of a composite seat cushion and a first outer side1B that defines the parameters of portion of the composite seat cushion.A second outer side 1C of the mold (only partially shown on the leftside of FIG. 1) defines the remaining parameters of a composite seatcushion to be formed by the mold 10. The mold 10, specifically eitherthe inner core 1A or the first 1B and second 1C outer sides, may bedesigned with varying thicknesses and sizes to provide a variety of seatcushion designs. The mold 10 can have more or less outer sides. The mold10 can also include a top 1D (not shown in FIG. 1 and FIG. 2). The mold10 may be designed to allow consistent quality to be maintained duringproduction. The mold 10 may be designed to hold other preformed parts ofthe final product that will eventually cure in the mold 10 during afinal step into one single piece or part as described in the exemplaryembodiment. The preformed components used in the composite seat cushionmay be produced in the same method of production (reaction injectionmolding) or consist of other prefabricated materials, such as, forexample, Styrofoam, that are fabricated to predetermined specifications.

FIG. 2, shows a view of the mold 10 of FIG. 1 that further includesprefabricated parts 20 inserted into the mold 10. The prefabricatedparts 20 can be, for example, knee pad inserts. The prefabricated parts20 can be made of a foam-like material that will, for example, adhere toa skin-like material, such as, for example, polyurethane. In anotherexample, a prefabricated part can be used in another portion of thecomposite seat cushion. For example, a prefabricated part can be used inan area besides a lateral side of the composite seat cushion, such as amiddle portion of a front and/or rear side of the composite seatcushion. Such prefabricated parts can vary in shape and size, as isneeded for different areas of the composite seat cushion. As shown inthe example of FIG. 2, a material 32 is added to the mold 10 that willform a composite seat cushion in the mold. The material 32 can be, forexample, a chemical mixture that forms an energy absorbent innerfoam-like structure and an outer skin-like structure. The material 32can be introduced into the mold 10 by a spray device 30, as shown in theexample of FIG. 2. The spray device 30 can be configured to spray thematerial 32 directly into the mold 10. Once a predetermined amount ofmaterial 32 has been applied, the mold 10 can be closed (with anyprefabricated parts disposed therein) by positioning the core 1A withinthe mold and positioning the top 1D in a closed, locked position asshown in FIG. 3. The chemical reaction is then allowed to take place forthe material 32 and any prefabricated parts 20 to form a compositecushion.

The material 32 can be a chemical mixture, such as a thermoset polymercommonly referred to as polyurethane. The material 32 may include atleast two materials, an isocyanate and a polyol that react in thepresence of a catalyst. A process for providing the material 32 can be,for example, reaction injection molding. The material 32 can have a makeup that will physically bind to any prefabricated materials 20 that areplaced within the mold 10 and become a part of the composite seatcushion. A primary chemical compound of the material 32 should adhere toany other prefabricated parts using the same process, if needed, to makeup the composite seat cushion, allowing for one single piece when afinal molding process is completed. The primary chemical compound canbe, for example, a thermoset polymer, such as polyurethane. The primarychemical compound may be designed to be flame retardant to minimizeflammability of the composite seat cushion. The mixture of material maybe varied to produce different mechanical characteristics, such as, forexample, a harder vs. a softer foam-like structure and/or a thicker vs.a thinner skin-like structure. The material may be selected so that acomposite seat cushion formed by the material may be repaired with acompound.

According to an exemplary embodiment, the material 32 for forming thecomposite seat foam structure can include environmentally-friendlymaterials. Such materials may help to reduce harmful emissions in theproduction process, such as the emission of fluorocarbons, and may bemore environmentally friendly than materials of conventional seatcushions when implemented.

According to another example, a first material, such as polyvinylchloride (PVC), may be introduced into the mold 10 and onto the interiorsurfaces of the mold 10 to form the outer skin of the composite seatcushion. The mold 10 may then be closed and a second material, such aspolyurethane, may be introduced into the mold 10 to form a foam-typematerial within the skin-forming material inside the mold. Such amixture of the second material may include a catalyst to promote achemical reaction for the second material. The first material and thesecond material can be selected and processed so that the skin formed bythe first material adheres to and is integrally bonded to the foam-typematerial formed by the second material.

FIG. 3 shows the mold 10 in a closed position. In this position thematerial 32 can chemically react, set, and form. For example, thematerial 32 may expand inside the mold 10 as the material 32 reaches itsboiling point. As the material 32 expands throughout the mold 10, themold 10 can act as a heat sink to help cool material 32 that comes incontact with the mold 10, causing a skin-like structure to form as amore dense polyurethane on the surface of the interior of the mold,which forms a skin-like outer surface of a composite seat cushion. Thematerial 32 within the closed mold 10 which does not come in directcontact with the mold cools slower and is less dense, forming a softerand energy absorbent foam beneath the skin-like outer surface. Thus, aseat cushion with a skinned foam that includes a skin integrally bondedto foam can be formed. Such a seat cushion can be a single piece ofskinned foam. The skin can be formed as an uninterrupted skin over theoutside of the entire composite seat cushion. The thickness of thecomposite seat cushion, such as the thickness of the foam-type material,can be varied to provide different predefined amounts of energyabsorption.

After the chemical compound has cured, the mold may be reopened, asillustrated in FIG. 4. The inner core 1A assists in the process ofremoving the formed composite seat cushion 50 from the outer side of themold 10 and can be used to form a cavity 53 inside the seat cushion 50,as shown in the example of FIG. 5. The cavity 53 can be configured toreceive at least one of a substantially upright back portion of a schoolbus seat frame and a substantially horizontal seat portion of the schoolbus seat frame. The composite seat cushion 50 is then ready to beremoved from the inner core 1A. Instead of the core 1A being anintegrated feature of the mold, as shown in the examples of thedrawings, the core could be consumable, i.e., destroyed in the processof making the composite seat cushion 50. Materials for such disposablecores include, for example, sand, powder, ceramics, and high temperaturefoam.

FIG. 5 shows an example of a composite seat cushion 50 having an “outer”skin surface 51 and an “inner” foam composition 52, according to anexemplary embodiment. The outer skin surface 51 may be textured and maybe flame retardant and meet flammability specifications set forth by theindustry, allowing a vinyl cover to be bypassed in favor of the outerskin surface alone. The foam composition of the material 32 used for theseat cushion 50 may be designed to provide energy absorption during acollision event to meet crash protection standards set forth by theindustry, depending upon the thickness of the foam.

FIG. 6 shows an example of the composite seat cushion 50 being removedfrom the mold 10, as viewed from the rear of the seat cushion 50. FIG. 6demonstrates how the mold may allow different amounts and shapes ofmaterial to be formed in specified areas in order to meet desired designcriteria, such as designated crash standards as set by the NationalHighway Traffic Safety Administration (NHTSA) for each particular partof a seat. The mold may be adjusted to allow the composite seat cushionto take any form necessary to fit for any given seat. For example, anindentation is visible between the lateral sides of the composite seatcushion of FIG. 6, demonstrating extra padding, energy absorption, andprotection on the lateral edges of the composite seat cushion.

The composite seat cushion constructed by the method illustrated inFIGS. 1-6 may have various properties. For example, different texturesor patterns may be “printed,” molded, or otherwise formed on the outsideof the seat foam (e.g., a logo or mascot of a school, or a school nameor nickname) and/or various colors of the outer cover of the seat foammay be used. It also can have lettering molded into the surface, suchas, for example, marketing items, logos, seat numbers, serial numbers,date of manufacture, and warnings. The construction of the compositeseat cushion permits having small details in design. Moreover, thecomposite seat cushion can include, for example, inserts (e.g., hardfoam, plastic, metal, wood, vinyl) that protrude from the material toprotect the material, secure the material to another area, or provideadditional features, such as drink holders or trays. The composite seatcushion also could have inserts (e.g., hard foam, plastic, metal, wood,or vinyl) that are completely covered by the material of the compositeseat cushion. The composite seat cushion can have dynamic structuralfeatures, such as ribs, contours, or ports.

The composite seat cushion also can have skin on all or only somesurfaces. The thickness of the skin can be adjusted across the compositeseat cushion. Contours can be provided on the surface. Additionally,open sections can be provided to accommodate future applications, suchas ports in the seat to handle belts or an opening for a TV or otherscreen. The composite seat cushion can have features used to indicateimpact, wear, or heavy use, such as breakaway striations in surface. Forexample, if the composite seat cushion is skinned with two colors, onewould show through the other. As a further example, the composite seatcushion can be a homogenous single part requiring no additionaloperations prior to use. The seat back and seat bottom could be moldedin a one piece design. Additionally, mounting features can be providedto secure the composite seat cushion to a frame.

FIG. 7 shows the varying thickness of foam created by the mold, andvarious other dimensions of a presently preferred composite seat cushion(measurements for a front part, a back part, and cavity). Exemplarydimensions can be as follows: length a can be 440-450 mm, or morepreferably 443.48 mm; length b can be 425-435 mm, or more preferably431.80 mm; length c can be 800-840 mm, or more preferably 820.42 mm;length d can be 560-580 mm, or more preferably 571.34 mm; length e canbe 660 to 680 mm, or more preferably 673.10 mm; length f can be 900-1100mm, or more preferably 1003.30 mm; angle g can be 70-90°, or morepreferably 84.0°; angle h can be 70-90°, or more preferably 80.0°;length i can be 590-610 mm, or more preferably 596.90 mm; length j canbe 70-80 mm, or more preferably 76.20 mm; length k can be 90-110 mm, ormore preferably 101.60 mm; length l can be 15-25 mm, or more preferably19.05 mm; length m can be 20-30 mm, or more preferably 25.40 mm; lengthn can be 20-30 mm, or more preferably 25.40 mm; radius o can 6-8 mm, ormore preferably 7.62 mm; radius p can be 140-150 mm, or more preferably152.40 mm; and length q can be 530-560 mm, or more preferably 546.35 mm.As another example, the shape of the composite seat cushion isillustrated with the use of angle measurements to illustrate the“incline” of the side of the composite seat cushion. The dimensions maybe altered, for example, by changing the dimensions of the mold 10 asdescribed in FIGS. 1 through 6.

FIGS. 8 through 11 illustrate a process of installing a composite seatcushion 50 on a seat frame, such as a seat frame of a bus. FIG. 8 showsa school bus seat back frame 70 without the composite seat cushion (notethat the legs of the seat frame are not shown). In FIG. 9, the compositeseat cushion is shown being placed over the seat back frame 70 of FIG.8, from a rear view. The composite seat cushion 50 may be designed suchthat the foam may be easily slid over the top of the seat frame 70 tocover a substantially upright back portion of the seat frame 70. Thedimensions of the composite seat cushion 50 may be adjusted toaccommodate different size and shape seat back frames 70. FIG. 10 showsthe composite seat cushion 50 in place over the seat frame 70, from arear view. The composite seat cushion 50 may “lock into place” in avariety of ways (e.g., fasteners, adhesives) or may simply be slid overthe seat frame 70 and stay stabilized. FIG. 11 shows the composite seatcushion 50 in place over a seat frame 80, from a front view.

According to alternative embodiments, the composite seat cushion 50 maybe installed in a variety of ways (e.g., being fastened to the seatframe, being slid onto the seat frame from the side or the bottom, etc.)and the construction of the composite seat cushion 50 may be adjustedaccordingly. For example, the composite seat cushion 50 may be a singlepiece or may be made up of multiple pieces. The composite seat cushion50 may be designed for a seat back frame 70, such as a substantiallyupright back portion of a seat back frame 70, or an entire seat frame80, such as a substantially horizontal seat portion in addition to, oralternatively to, a back portion of the entire seat frame. The seatframe 80 can be the frame for a vehicle seat, such as a school bus benchseat. Additional padding may or may not be used in conjunction with thecomposite seat cushion 50 to completely encase the seat frame. Thoughthe composite seat cushion 50 is shown in the drawings with a slip-onconfiguration, it also may be created in a manner to encapsulate theframe or any structure it is intended to mate with. It also could bemolded around the frame itself to create a one-piece unit. The compositeseat cushion 50 can also be designed so that a bottom of the seatcushion can be wrapped around a seat frame and secured with a fastener,such as a hook and loop fastener, such as Velcro, buttons, and otherfastening devices known in the art.

Many configurations and dimensions of the composite seat cushion arepossible, and the composite seat cushion may be adjusted to providedadded safety features, such as outward extending portions, such as, forexample, side barriers and other dimensions, to help provide additionalcompartmentalization and/or containment to passengers. This increasesthe intended safety by helping to contain passengers within their highlypadded seats during the event of a collision and/or rollover.Additionally, a mold that is used to form the composite seat cushion maybe designed or configured to produce a composite seat cushion with theadded safety features built in.

FIG. 12 shows an alternative configuration of a composite seat cushion56 having an outward extending portion, such as a wall or aisle sidebarrier 12A, according to an exemplary embodiment. As shown in theexample of FIG. 12, the wall or aisle side barrier 12A can extend in anaisle direction of a vehicle, such as a school bus. The side barrier 12Acan further compartmentalize and contain passengers and can preventpassengers or objects from being thrown from a seat, such as into theaisle of the bus (e.g., during an off-camber collision). The sidebarrier 12A may be formed on either side of the composite seat cushion56, such as for protecting the aisle side and the wall side of thepassenger in the seat. The side barrier 12A can be formed as part of thecomposite seat cushion 56 during the molding process by adjusting theshape of the mold.

FIG. 13 shows another alternative configuration of a composite seatcushion 58 having an outward extending portion, such as a curvature 13Adesigned to provide further compartmentalization and containing for thepassengers seated directly behind the outward extending curvature 13A.As shown in the example of FIG. 13, the outward extending curvature 13Acan extend across a rear surface of a school bus seat along a width ofthe school bus seat. The rear portion of the composite seat cushion 58includes the outward extended curvature 13A, which can, for example, bedesigned to reduce injuries from serious collisions, such as during arollover of a vehicle. The outward extended curvature 13A can be formedas part of the composite seat cushion 58 during the molding process byadjusting the shape of a mold that the composite seat cushion 58 is madein.

FIG. 14 illustrates seats 59 having the features of the composite seatcushions of FIGS. 12 and 13 lined up in a sequential manner, as would betypical, for example, on a standard bus, according to an exemplaryembodiment. FIG. 15 is an opposite side view of the seats of FIG. 14.FIGS. 14 and 15 illustrate how the features described in FIGS. 12 and 13may be combined to provide compartmentalization across a vehicle, suchas the entire bus. The sequential manner in which the seat foams areinstalled allow for each passenger to be provided a degree of protectionfrom rollovers in a collision event by the seat foam in front of him orher.

Referring to the example of FIG. 16, the seats 59 of FIGS. 12 through 15are shown, but with more dramatic features that could further enhancethe compartmentalized (e.g., passive restraint) safety offered by theseats 59. The features described in FIGS. 12 and 13 are more pronounced.The aisle side barrier 12A of FIG. 12 is shown as expanded in FIG. 16.The expanded side barrier 16A may be designed to protect more of thebody and head of the passenger. The outward extended curvature 13A ofFIG. 13 is shown as being more pronounced in the example of FIG. 16. Theoutward extended curvature 16B may be designed to further restrictpassenger movement in the case of a collision event. The space outlinedby 16C illustrates an exemplary position of the lower body of apassenger when in a vehicle, such as a bus. The various featuresillustrated in the examples of FIGS. 12 through 16 may be adjusted basedon average passenger sizes. For example, more pronounced features asshown in FIG. 16 may be used in school buses where the average passengersize is relatively smaller.

FIG. 17 shows another embodiment of a composite seat cushion. Variousother safety features, for example seat belts, may be used inconjunction with the composite seat cushion. Seat belts 17A (e.g.,three-point lap seat belts, shoulder belts, other types of seat beltsand seat belt implementations) can be implemented in conjunction withthe composite seat cushion. Seat belts 17A may be attached to the seatframe of the seat and fit through notches or holes in the composite seatcushion, or seat belts 17A may be fastened to the composite seat cushionin various manners. Seat belts 17A may be designed with seat beltbuckles, or passengers may not need a buckling feature to properly usethe seat belts.

The ability to shape the seat back can also be used to integrate withactive restraints such as seat belts. When seat belts are used on avinyl covered bench seat, typical to those currently being used on aschool bus, passengers may be seated improperly, thereby diminishing thesafety offered by the restraint. By molding the seat into dimensionsconsistent with the anthropology of student passengers, correct posturewithin the given seat can be maximized and therefore make best use ofactive restraints as intended. For example, the use of seat belts 17Amay be accompanied by a special composite seat cushion design thatpromotes proper posture of a seated passenger. The composite seatcushion may be molded such that correct posture is encouraged.

The maintainability of the composite seat cushion may be advantageouslyimproved compared to the maintainability of conventional seat cushions.For example, the composite seat cushion of the present invention may beremoved from the seat frame by simply lifting and sliding the compositeseat cushion off the seat back frame. This may allow for easiermaintenance of the composite seat cushion. The composite seat cushionmay be made of a composite material such that repairs to cuts or tearsin the composite seat cushion may be mended by the use of a specialcompound. For example, polyurethane may be sprayed onto the outerskin-type surface and molded inner foam.

It is important to note that the construction and arrangement of thecomposite seat cushion as shown in the various exemplary embodiments isillustrative only. Although only a few embodiments have been describedin detail in this disclosure, those skilled in the art who review thisdisclosure will readily appreciate that many modifications are possible(e.g., variations in sizes, dimensions, structures, shapes andproportions of the various elements, values of parameters, mountingarrangements, use of materials, colors, orientations, etc.) withoutmaterially departing from the novel teachings and advantages of thesubject matter disclosure herein. For example, elements shown asintegrally formed may be constructed of multiple parts or elements, theposition of elements may be reversed or otherwise varied, and the natureor number of discrete elements or positions may be altered or varied.Accordingly, all such modifications are intended to be included withinthe scope of the present application. The order or sequence of anyprocess or method steps may be varied or re-sequenced according toalternative embodiments. Other substitutions, modifications, changes andomissions may be made in the design, operating conditions andarrangement of the exemplary embodiments.

1. A cushion for a school bus seat, comprising: a single piece ofskinned foam including foam and a skin integrally bonded to the foam;and a cavity in the single piece of skinned foam and configured toreceive at least one of a substantially upright back portion of a schoolbus seat frame and a substantially horizontal seat portion of the schoolbus seat frame, wherein the single piece of skinned foam is configuredto be disposed over and to cover at least one of the substantiallyupright back portion and the substantially horizontal seat portion. 2.The cushion for a school bus seat of claim 1, wherein the single pieceof skinned foam includes an outward extending portion that is configuredto compartmentalize and contain passengers.
 3. The cushion for a schoolbus seat of claim 2, wherein the outward extending portion includes awall disposed to extend in an aisle direction of a school bus.
 4. Thecushion for a school bus seat of claim 2, wherein the outward extendingcurvature extends across a rear surface of the school bus seat along awidth of the school bus seat.
 5. The cushion for a school bus seat ofclaim 1, wherein the single piece of skinned foam is configured toreceive a shoulder seat belt.
 6. A method of making at least a portionof a school bus seat, comprising: disposing within a mold a material forforming a skin of the school bus seat; disposing on the material a foammaterial to form a single piece of skinned foam; wherein the singlepiece of skinned foam is configured to be disposed over and to cover atleast one of a substantially upright back portion of a frame of a schoolbus seat and a substantially horizontal seat portion of a frame of aschool bus seat.
 7. The method of claim 6, wherein the skin isintegrally bonded to the foam.
 8. The method of claim 6, furthercomprising forming a cavity in the single piece of skinned foam andconfigured to receive at least one of the substantially upright backportion and the substantially horizontal seat portion.
 9. The method ofclaim 6, further comprising disposing the single piece of skinned foamover and covering at least one of the substantially upright back portionand the substantially horizontal seat portion.